US6515085B1 - Components and catalysts for the polymerization of olefins - Google Patents

Components and catalysts for the polymerization of olefins Download PDF

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Publication number
US6515085B1
US6515085B1 US08/371,048 US37104895A US6515085B1 US 6515085 B1 US6515085 B1 US 6515085B1 US 37104895 A US37104895 A US 37104895A US 6515085 B1 US6515085 B1 US 6515085B1
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Prior art keywords
polymerization
dihalide
supported
catalysts
olefins
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Sandro Parodi
Roberto Nocci
Umberto Giannini
Pier Camillo Barbe'
Umberto Scata'
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Basell Poliolefine Italia SRL
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Basell Poliolefine Italia SRL
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/02—Carriers therefor
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/62—Refractory metals or compounds thereof
    • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts

Definitions

  • the supported highly active and highly stereospecific catalysts for the polymerization of propylene and higher olefins known up to now are obtained by the reaction of an Al alkyl compound partially complexed with an electron-donor compound (outside donor) with a solid component comprising a Ti compound and an electron-donor compound (inside donor) supported on a Mg dihalide in active form.
  • Those supported catalysts require the use of an inside donor in order to obtain polymers having a high isotactic index. If the inside donor is omitted, polymers having a low isotactic index are obtained.
  • One object of this invention is to provide catalyst components which comprise a silicon compound as defined herein-above and which yield catalysts that polymerize the alpha-olefins to high yields of polymers having a high isotacticity index.
  • the activity and stereospecificity of the catalysts can be further increased if the silicon compound used as outside donor is present as inside donor also in the Ti-containing Mg dihalide-supported component in amounts corresponding to molar ratios between the silicon compound and the supported halogenated Ti- compound comprised between 0.1 and 5.
  • catalysts which are known which are prepared by using, as both inside and outside donor, a silicon compound containing Si—O—C bonds and the activity and stereospecificity of which are not increased over the activity and stereospecificity obtainable with catalysts in which an ester of benzoic acid is used as inside and outside donor.
  • the catalysts of this invention comprise the product of the reaction between the following components:
  • a solid comprising, as essential support, an anhydrous Mg dihalide in the active form as defined infra and, supported on said dihalide, a Ti halide or Ti haloalcoholate, or the solid (c) containing supported therein also a silicon compound as defined in (b) in an amount corresponding to a molar ratio between the supported silicon compound and the supported halogenated Ti compound comprised between 0.1 and 5.
  • the active anhydrous Mg dihalides forming the essential support of component (c) are the Mg dihalides showing in the X-rays powder spectrum of component (c) a broadening of at least 30% of the most intense diffraction line which appears in the powder spectrum of the corresponding dihalide having 1 m 2 /g of surface area, or are the Mg dihalides showing an X-rays powder spectrum in which said most intense diffraction line is replaced by a halo with the intensity peak shifted with respect to the interplanar distance of the most intense line; and/or are the Mg dihalides having a surface area greater than 3 m 2 /g.
  • the measurement of the surface area of the Mg dihalides is made on component (c) after treatment with boiling TiCl 4 for 2 hours. The found value is considered as surface area of the Mg dihalide.
  • Very active forms of Mg dihalides are those giving an X-rays powder spectrum in which the most intense diffraction line appearing in the spectrum of the corresponding halide having 1 m 2 /g of surface area is decreased in relative intensity and broadened to form a halo, or are those in which said most intense line is replaced by a halo having its intensity peak shifted with respect to the interplanar distance of the most intense line.
  • the surface area of the above forms is higher than 30-40 m 2 /g and is comprised in particular between 100-300 m 2 /g.
  • Active forms are also those deriving from the above forms by heat-treatment in inert hydrocarbon solvents and showing, in the X-rays spectrum, sharp diffraction lines in place of the halos.
  • the sharp, most intense line of these forms shows a broadening of at least 30% with respect to the corresponding line of the Mg dihalide having 1 m 2 /g of surface area.
  • Mg dihalides are Mg dichloride and Mg dibromide.
  • the content in water of the dihalides is generally less than 1% by weight.
  • Ti halides or Ti haloalcoholates and esters supported on the active Mg dihalide is meant the above compound which may be chemically or physically fixed on the support, and not extractable from component (c) by treatment of the same with boiling 1,2-dichloroethane for 2 hours.
  • Components (a), (b) and (c) are made to react with each other in any order; preferably, however, components (a) and (b) are premixed before being contacted with component (c).
  • the pre-mixing of (a) and (b) is conducted at temperatures comprised, usually, between room temperature and the temperature used in the polymerization process.
  • component (b) is made to react in a molar ratio with respect to the halogenated Ti compound supported on component (c) of at least 1 and in a molar ratio with respect to the Al alkyl compound used as component (a) of less than 20 and preferably comprised between 0.05 and 0.3.
  • the molar ratio between the Mg dihalide and the halogenated Ti compound supported therein is comprised between 1 and 500 and the molar ratio between said halogenated Ti compound and the electron-donor supported on the Mg dihalide is comprised between 0.1 and 50.
  • the silicon compounds set forth in (b) include compounds of general formula:
  • R is an alkyl, alkenyl, aryl, arylalkyl or cycloalkyl radical with from 1 to 20 carbon atoms;
  • Y is an —OR′, —OCOR′, —NR′ 2 group wherein R′, either equal to or different from R, has the same meaning as R;
  • X is either a halogen or hydrogen atom or an —OCOR′′ or —NR′′ 2 group wherein R′′, either equal to or different from R′, has the same meaning as R′;
  • n and p are numbers comprised, respectively, between: 0 and 3 for m, 1 and 4 for n and 0 and 1 for p; and m+n+p is equal to 4.
  • silicon compounds that may be used are compound in which two or more silicon atoms are bound to each other through oxygen or nitrogen atoms.
  • Preferred silicon compounds are: phenylalkoxysilanes such as phenyltriethoxy or trimethoxysilane, diphenyldimethoxy and diethoxysilane, monochlorophenyldiethoxysilane; alkylalkoxysilanes as, e.g., ethyltriethoxysilane and ethyltriisopropoxysilane.
  • Examples of other suitable compounds are: chlorotriethoxysilane, acetoxytriethoxysilane, vinyltriethoxysilane, butyltriethoxysilane, triphenylmonoethoxysilane, phenyltricycloethoxysilane, phenyldiethoxydiethylaminosilane, tetraphenoxysilane and tetralkoxysilanes such as tetramethoxysilane.
  • the silicon compound can be also formed in situ by reaction of, for instance, a halogenated silicon compound such as SiCl 4 with an alcohol or an alcoholate of Mg or Al.
  • the silicon compound is present in a combined form in the solid product of the reaction between the various catalyst-forming components, in a molar ratio between the silicon compound and the halogenated Ti compound greater than 0.05 and generally comprised between 0.1 and 5.
  • the Al alkyl compounds forming component (a) include Al trialkyls as, for instance, Al triethyl, Al triisobutyl, Al triisopropyl, and compounds containing two or more Al atoms linked to each other through hetero-atoms as:
  • Al alkyl compounds in which Al atoms are linked through groups such as SO 4 or SO 3 are also suitable.
  • Al alkyl compounds may be used in mixture with Al alkyl halides, e.g., AlEt 2 Cl.
  • Component (c) is prepared according to various methods, one of which, and also one of the preferred methods, consists in co-milling the Mg dihalide, the Ti halide or Ti haloalcoholate and the silicon compound when it is used, until appearance in the X-rays spectrum of the milled product of the modifications above set forth for the spectrum of the Mg dihalide and in heat-treating the milled product in suspension in a halogenated hydrocarbon as, e.g., 1,2 dichloroethane, separating the solid product and washing it with heptane or a similar hydrocarbon solvent.
  • the duration of the treatment is generally comprised between 1 and 4 hours and depends on the temperature of treatment.
  • an adduct between a Mg dihalide and an alcohol is reacted with TiCl 4 .
  • the reactions are described in Belgian patent 868,682 and published German patent No. 3,022,738.
  • the final product contains a Mg dihalide, present in the active form as set forth supra.
  • the Ti halides or Ti halogenalcoholates include, in particular, the Ti tetrahalides, Ti trihalides and Ti trihalogenalcoholates.
  • Preferred compounds are: TiCl 4 , TiBr 4 , 2,6-dimethylphenoxytrichlorotitanium.
  • the Ti trihalides are obtained according to known methods, for instance by reduction of TiCl 4 with Al or an organometallic Al compound or with hydrogen.
  • Ti trihalides it may be convenient, for the purpose of improving the performance of the catalysts, to carry out an oxidization, even if partial, of the titanium, either during or after the preparation of component (c).
  • halogens iodine halides.
  • Preferred catalysts are those in which: component (c) is obtained from MgCl 2 , TiCl 4 a silicon compound selected from the groups of phenyl or ethyltriethoxysilane or diphenyldimethoxy or diethoxysilane, and
  • Component (a) is an Al trialkyl, such as Al triethyl or Al triisobutyl.
  • One of the preferred methods of preparing component (c) consists in co-milling MgCl 2 , TiCl 4 and the silicon compound and in treating the milled product with a halogenated hydrocarbon such as, for instance, 1,2-dichloroethane.
  • the catalysts according to this invention are used to polymerize the alpha-olefins according to known methods, that is, by carrying out the polymerization in a liquid phase, either in the presence or absence of an inert hydrocarbon solvent, or in gas phase or by combining, for instance, a liquid phase polymerization step with a gas phase step.
  • the polymerization temperature is comprised between 40° and 160° C., but preferably between 60° and 90° C., operating either at atmospheric or at greater than atmospheric pressure.
  • the catalysts are particularly suitable for polymerizing propylene, butene-1, styrene and 4-methylpentene.
  • the catalysts may also be used according to known methods to polymerize mixtures of propylene and ethylene to form modified polypropylenes having improved shock-resistance at low temperatures (the so called block copolymers of propylene and ethylene) or to obtain random crystalline copolymers of propylene with minor proportions of ethylene.
  • Example 1 of the Belgian patent No. 868,682 is the same as Example 1 in each of its U.S. counterparts, Nos. 4,294,721 and 4,439,540.
  • the catalytic component thus prepared showed an X-rays powder spectrum in which the most intense diffraction line appearing in the spectrum of MgCl 2 having 1 m 2 /g of surface area was decreased in relative intensity and broadened to form a halo.
  • Example 1 was repeated but using a solid catalytic component prepared as follows:
  • Anhydrous MgCl 2 , phenyltriethoxysilane in molar ratio Mg/Si of 6, and TiCl 4 in molar ratio of 1:1 with respect to the phenyltriethoxysilane were co-milled in a vibrating mill of the type VIBRATOM manufactured by N. V. Tema's Gravenhage, Holland, having a total volume of one liter and containing 3 kg of stainless steel balls of 16 mm diameter.
  • Grinding was effected employing a filling coefficient equal to 100 g/l of total volume (vacuum), at an interior temperature of the mill of 25° C., and with grinding time of 72 hours.
  • the catalytic components thus prepared showed an X-rays powder spectrum in which the most intense diffraction line appearing in the spectrum of MgCl 2 having 1 m 2 /g of surface area was decreased in relative intensity and broadened to form a halo.
  • the solid catalytic component obtained was used in the polymerization of propylene under the same polymerization conditions described in Example 1. The results of the polymerization have been reported in Table I.
US08/371,048 1980-08-13 1995-01-10 Components and catalysts for the polymerization of olefins Expired - Lifetime US6515085B1 (en)

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Application Number Priority Date Filing Date Title
US08/371,048 US6515085B1 (en) 1980-08-13 1995-01-10 Components and catalysts for the polymerization of olefins

Applications Claiming Priority (14)

Application Number Priority Date Filing Date Title
IT8024141A IT1209255B (it) 1980-08-13 1980-08-13 Catalizzatori per la polimerizzazione di olefine.
IT24141A/80 1980-08-13
US29215781A 1981-08-12 1981-08-12
US55540083A 1983-11-28 1983-11-28
US78704385A 1985-10-15 1985-10-15
US87352286A 1986-06-12 1986-06-12
US2705587A 1987-03-23 1987-03-23
US24459488A 1988-09-13 1988-09-13
US51823790A 1990-05-07 1990-05-07
US62902190A 1990-12-18 1990-12-18
US75977691A 1991-09-13 1991-09-13
US7324593A 1993-06-04 1993-06-04
US21700294A 1994-03-23 1994-03-23
US08/371,048 US6515085B1 (en) 1980-08-13 1995-01-10 Components and catalysts for the polymerization of olefins

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US21700294A Continuation 1980-08-13 1994-03-23

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US08/371,048 Expired - Lifetime US6515085B1 (en) 1980-08-13 1995-01-10 Components and catalysts for the polymerization of olefins
US08/439,678 Expired - Lifetime US5539067A (en) 1980-08-13 1995-05-12 Components and catalysts for the polymerization of olefins
US08/469,735 Expired - Lifetime US6194342B1 (en) 1980-08-13 1995-06-06 Components and catalysts for the polymerization of olefins
US08/469,734 Ceased US5618771A (en) 1980-08-13 1995-06-06 Components and catalysts for the polymerization of olefins

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US08/469,735 Expired - Lifetime US6194342B1 (en) 1980-08-13 1995-06-06 Components and catalysts for the polymerization of olefins
US08/469,734 Ceased US5618771A (en) 1980-08-13 1995-06-06 Components and catalysts for the polymerization of olefins

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US (4) US6515085B1 (fr)
EP (4) EP0045977B2 (fr)
JP (11) JPS5763311A (fr)
KR (3) KR840000803B1 (fr)
AR (1) AR244254A1 (fr)
AT (4) ATE42311T1 (fr)
AU (3) AU557334B2 (fr)
BR (3) BR8105190A (fr)
CA (3) CA1185961A (fr)
CS (2) CS226437B2 (fr)
DE (4) DE3177032D1 (fr)
DK (3) DK163248C (fr)
ES (3) ES504716A0 (fr)
FI (3) FI70030C (fr)
HU (3) HU186399B (fr)
IN (3) IN154898B (fr)
IT (1) IT1209255B (fr)
MX (3) MX159065A (fr)
NO (3) NO159282C (fr)
PH (3) PH17760A (fr)
PL (3) PL140239B1 (fr)
PT (3) PT73500A (fr)
RU (1) RU2111975C1 (fr)
SG (1) SG33087G (fr)
SU (2) SU1457813A3 (fr)
YU (3) YU42418B (fr)
ZA (3) ZA815491B (fr)

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US7875679B2 (en) 2002-03-14 2011-01-25 Bassell Poliolefine Italia S.P.A. Polypropylene resin composition and film thereof
US20050165166A1 (en) * 2002-03-14 2005-07-28 Tetsuya Fudaba Polypropylene resin composition and film thereof
US20070122577A1 (en) * 2003-09-22 2007-05-31 Showa Denko Plastic Products Co., Ltd. Polypropylene-base molded article and container
US7256151B2 (en) 2004-05-31 2007-08-14 Sumitomo Chemical Company Limited Solid catalyst component for α-olefin polymerization, process for producing catalyst therefor, and process for producing α-olefin polymer
US20050267272A1 (en) * 2004-05-31 2005-12-01 Sumitomo Chemical Company, Limited Solid catalyst component for alpha-olefin polymerization, process for producing catalyst therefor, and process for producing alpha-olefin polymer
US20090156748A1 (en) * 2005-11-22 2009-06-18 Basell Poliolefine Italia S.R.L. Polyolefin Compositions Having Low Gloss
US20090283935A1 (en) * 2005-11-22 2009-11-19 Basell Poliolefine Italia S.R.L Impact Resistant Polyolefin Compositions
US7872074B2 (en) 2005-11-22 2011-01-18 Basell Poliolefine Italia S.R.L. Impact resistant polyolefin compositions
US8722808B2 (en) 2005-11-22 2014-05-13 Basell Poliolefine Italia S.R.L. Polyolefin compositions having low gloss
US20100305285A1 (en) * 2007-11-27 2010-12-02 Mitsui Chemicals, Inc. Solid titanium catalyst component, olefin polymerization catalyst, and olefin polymerization process
US8742040B2 (en) 2007-11-27 2014-06-03 Mitsui Chemicals, Inc. Solid titanium catalyst component, olefin polymerization catalyst, and olefin polymerization process
US20100285255A1 (en) * 2007-12-28 2010-11-11 Basell Poliolefine Italia S.R.L. Plastic tanks made from random copolymers of propylene and hexene-1
US8252399B2 (en) 2007-12-28 2012-08-28 Basell Poliolefine Italia S.R.L. Plastic tanks made from random copolymers of propylene and hexene-1
US20110165416A1 (en) * 2008-07-10 2011-07-07 Mitsui Chemicals, Inc. 4-methyl-1-pentene polymer, resin composition containing 4-methyl-1-pentene polymer, masterbatch thereof, and formed product thereof
US8765872B2 (en) 2008-07-10 2014-07-01 Mitsui Chemicals, Inc. 4-methyl-1-pentene polymer, resin composition containing 4-methyl-1-pentene polymer, masterbatch thereof, and formed product thereof
US9657117B2 (en) 2008-07-10 2017-05-23 Mitsui Chemicals, Inc. 4-methyl-1-pentene polymer, resin composition containing 4-methyl-1-pentene polymer, masterbatch thereof, and formed product thereof
US9153757B2 (en) 2011-08-01 2015-10-06 Mitsui Chemicals, Inc. Thermoplastic resin composition for reflective material, reflective plate, and light-emitting diode element
US10619039B2 (en) 2012-09-18 2020-04-14 Prime Polymer Co., Ltd. Polypropylene resin composition and use thereof
US10011715B2 (en) 2012-11-19 2018-07-03 Mitsui Chemicals, Inc. Polyester resin composition, manufacturing method therefor, and camera module containing said polyester resin composition
US10072171B2 (en) 2013-06-07 2018-09-11 Mitsui Chemicals, Inc. Olefin-based paint containing propylene/α-olefin copolymer
US11192965B2 (en) 2016-01-14 2021-12-07 Toho Titanium Co., Ltd. Solid catalyst component for olefin polymerization, catalyst for olefin polymerization, and method for producing olefin polymer

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ATE48144T1 (de) 1989-12-15
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PT73500A (en) 1981-09-01
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PT73499B (en) 1985-11-12
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ZA815491B (en) 1982-08-25
IT8024141A0 (it) 1980-08-13
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EP0045977B1 (fr) 1987-01-07
US5539067A (en) 1996-07-23
JPH06293806A (ja) 1994-10-21
FI812440L (fi) 1982-02-14
JPS5763310A (en) 1982-04-16
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JPH0475245B2 (fr) 1992-11-30
PT73499A (en) 1981-09-01
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JPS5763311A (en) 1982-04-16
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FI812442L (fi) 1982-02-14
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FI70030B (fi) 1986-01-31
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US5618771A (en) 1997-04-08
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RU2111975C1 (ru) 1998-05-27
JPH0338285B2 (fr) 1991-06-10
FI70029B (fi) 1986-01-31
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